Inverted low loss relay structure

ABSTRACT

The following specification sets forth a structure defining an electrical relay of the direct current high amperage type adapted for automotive use and in which the relay contacts are so arranged relative to the terminals as to provide a short low resistance path.

United States Patent [191 Hayden Dec. 25, 1973 INVERTED LOW LOSS RELAYSTRUCTURE [75] Inventor: Rodney Hayden, Stacy Creek,

Ontario, Canada [73] Assignee: TRW Inc., Cleveland, Ohio 22 Filed: Sept.25, 1972 [21] Appl. No.: 291,867

[52] US. Cl. 335/187, 335/203 [51] Int. Cl. HOlh 50/14 [58] Field ofSearch 335/185, 187, 203

[56] References Cited UNITED STATES PATENTS 3,138,678 6/1964 Raab335/187 3,588,765 6/1971 Alten 335/203 Primary ExaminerHarold BroomeAttorney-Philip B. Parker et al.

[5 7] ABSTRACT The following specification sets forth a structuredefining an electrical relay of the direct current high amperage typeadapted for automotive use and in which the relay contacts are soarranged relative to the terminals as to provide a short low resistancepath.

4 Claims, 2 Drawing Figures INVERTED LOW LOSS RELAY STRUCTURE Thisinvention relates to an inverted low loss relay structure adapted fordirect current automotive use.

In recent years certain relay controlled circuits in automobiles havebeen required to handle larger currents whereas formerly a twenty ampererating relay circuit was regarded as a heavy current circuit. In presentautomobile circuitry there is a requirement for the relay switching ofcurrents of forty amperes, sixty amperes and as much as eighty amperesin some control devices. In the past, heavy current relays in suchapplication have been characterized by a noticeable power and heat lossdue to the resistance of the connection within the relay between therelay contacts and the relay terminals. Generally, relay structures inautomobile applications have been of the upstanding type, that is to saythe relay coil stands on a base and the terminals extend from the base,the relay contacts associated with armature mechanism being superposedabove the relay coil remote from the base. In such relay structures thebase supports a housing enclosing the relay components and the relayterminals extend from the base in the form of plug-in tynes or prongsadapted to be inserted into a receiving socket. Thus the relay structureof the prior art necessitates an electrical connection of a lengthsubstantially equal to the length of the coil extending between therelay contacts and the relay terminals in the base.

It is an object of the invention to provide a relay structure for directcurrent automobile heavy current use in which the components arearranged in an inverted manner to locate the relay contacts immediatelynext to the relay terminals to provide an electrical path between theterminals and the contacts of minimum length.

It is another object of the invention to provide an inverted relaystructure comprising a minimum number of sturdy simple components of lowvoltage loss.

Other objects of the invention will be appreciated by a study of thefollowing specification taken in conjunction with the accompanyingdrawings.

IN THE DRAWINGS FIG. lis a cutaway aerial perspective view of aninverted relay according to the invention;

FIG. 2 is a side elevation of the relay of FIG. 1 with the cover orhousing removed.

Referring to the drawings, the inverted relay of the invention comprisesa moulded base 11 formed of insulating material with the terminals 12,I3, 14 and 15 fixed in the base during the moulding operation. Base 11in peripheral recess 16 is adapted to tensionably receive the housing 17extending thereabove to enclose the relay structure therewithin andabove said base. Contact terminal 15 rises through base 11 and extendslaterally over the upper surfaces 18 of the base to provide a rigidmetal platform portion 19 on which is mounted the relay armature member20 held thereon by mounting flange 21 of a stationary, inverted U-shaped core member 22, flange 21 and armature 20 support platformportion 19 and base 11 being fastened rigidly together by a generousrivet 23. The depending arm 24 of core 22 carries a relay coil 25 on acoil form structure 26, the free end 27 of the stationary core partbeing spaced by a gap 28 from the movable core part 29 fastened to thearmature 20in a position adapted to complete the magnetic circuit of thecore 22 upon current flowing in coil 25. The free end 30 of the armaturecarries a generous relay contact 31 normally defining a contact gap 32with the superposed stationary contact 33 rigidly depending from thecontact arm 34 of contact terminal member 13. It will be observed thatthe thickness of platform 19 serves to space the armature 20 from theupper surfaces 18 of the base 11 and that such platform serves the dualpurpose of a mounting for the core as well as an electrical connectionfrom the armature and its movable contact to the terminal 15 therebyderiving a number of advantages from the simplicity of this arrangementand especially a short current conducting path. The coil 25 connects-byits leads 35, 36 to coil terminals 14 and 12.

It will be observed that the arrangement of relay components of theinvention is such as to provide for the assembly of the core, flexiblearmature, movable contact, terminal and base with one rivet in suchmanner that the armature is located nearest the base in proximity to theinner surface thereof to enable the flange 19 to be as short as possibleand flange 34 in association with its terminal portion 13 to be ofminimum length. In this arrangement which may be regarded as of theinverted type the relay contacts are located between the base and therelay coil.

I claim:

1. In a low loss high current relay having a relay winding, a stationarycore part supporting the winding, a flexible relay armature strip havinga contact on its free end and carrying a movable core part, a fixedcontact adapted to be engaged by said first relay contact and a base ofan insulating material, a contact terminal arrangement comprising: anarmature terminal extending through the base and having a large,contacting flange overlying and in engagement with the inner surfaces ofthe base and supporting a portion of said stationary core part, theother end of said armature strip being supported and fixed between saidstationary core part supporting portion and said contacting flange tolocate said armature strip in close proximity to said armature terminaland said base and between said base and said stationary core part; and alarge fixed contact terminal extending through said base and embodyingan integral contact mounting flange adapted to locate the fixed contactof the relay in a position for engagement by said first relay contact onthe free end of said armature strip.

2 A low loss high current relay contact terminal arrangement accordingto claim 1 wherein a single rivet connects said stationary core partportion, said armature strip, said armature terminal flange and saidbase ina rigid assembly.

3 A low loss high current relay contact terminal arrangement accordingto claim 1 wherein said armature terminal and said fixed contactterminal, including the flange portions thereof, are of minimum length.

4. A low loss high current relay comprising a base of insulatingmaterial, an armature terminal extending through said base and having alarge, integral contacting flange overlying and engaging the innersurface of said base, a flexible relay armature strip carrying a movablecontact on its free end and having a fixed end overlying and inengagement with said flange on said armature terminal and carrying amovable core part between its fixed end and said movable contact, alarge fixed contact terminal extending through said base and having ashort, integral flange spacedly overlying said base and carrying a fixedcontact positioned for engagement by said movable contact, a stationarycore part having a first portion in the form of a short, substantiallyplanar, supporting flange and 'a second portion of a substantiallyinverted U" shape having one leg joined to said supporting flange andanother leg spaced from said one leg and terminating in a free end, anda relay coil mounted on said other leg of said stationary core part,said stationary core part supporting flange overlying said armatureterminal contacting flange and said fixed end of said armature stripbeing disposed between said flanges, said end of said strip and saidflanges being clamped together and to said base by a rivet connection,said free end of said other leg of said stationary core part beingdisposed spacedly above said movable core part, and said fixed andmovable contacts for use in high current applications.

1. In a low loss high current relay having a relay winding, a stationarycore part supporting the winding, a flexible relay armature strip havinga contact on its free end and carrying a movable core part, a fixedcontact adapted to be engaged by said first relay contact and a base ofan insulating material, a contact terminal arrangement comprising: anarmature terminal extending through the base and having a large,contacting flange overlying and in engagement with the inner surfaces ofthe base and supporting a portion of said stationary core part, theother end of said armature strip being supported and fixed between saidstationary core part supporting portion and said contacting flange tolocate said armature strip in close proximity to said armature terminaland said base and between said base and said stationary core part; and alarge fixed contact terminal extending through said base and embodyingan integral contact mounting flange adapted to locate the fixed contactof the relay in a position for engagement by said first relay contact onthe free end of said armature strip. CM,2 loss high current relaycontact terminal arrangement according to claim 1 wherein a single rivetconnects said stationary core part portion, said armature strip, saidarmature terminal flange and said base in a rigid assembly. CM,3 losshigh current relay contact terminal arrangement according to claim 1wherein said armature terminal and said fixed contact terminal,including the flange portions thereof, are of minimum length.
 4. A lowloss high current relay comprising a base of insulating material, anarmature terminal extending through said base and having a large,integral contacting flange overlying and engaging the inner surface ofsaid base, a flexible relay armature strip carrying a movable contact onits free end and having a fixed end overlying and in engagement withsaid flange on said armature terminal and carrying a movable core partbetween its fixed end and said movable contact, a large fixed contactterminal extending through said base and having a short, integral flangespacedly overlying said base and carrying a fixed contact positioned forengagement by said movable contact, a stationary core part having afirst portion in the form of a short, substantially planar, supportingflange and a second portion of a substantially inverted ''''U'''' shapehaving one leg joined to said supporting flange and another leg spacedfrom said one leg and terminating in a free end, and a relay coilmounted on said other leg of said stationary core part, said stationarycore part supporting flange overlying said armature terminal contactingflange and said fixed end of said armature strip being disposed betweensaid flanges, said end of said strip and said flanges being clampedtogether and to said base by a rivet connection, said free end of saidother leg of said stationary core part being disposed spacedly abovesaid movable core part, and said fixed and movable contacts beingdisposed between said base and said relay coil, the spacing between saidlegs of said inverted ''''U''''-shaped stationary core part portionbeing substantially less than the length of said relay coil whereby thelength of the current path between said contacts, when engaged, and saidarmature terminal is rendered minimal thereby providing a relay which ishighly efficient for use in high current applications.